HUSKIE
HYDRAULIC
HAMMERS
SERVICE
MANUAL
HH1500
HH2000
HH3600
HH4500
HH5800
HH8000
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1. SAFETY INFORMATION
• Always read the information in this manual before operating the hammer. Failure to
do so can result in personal injury or damage to the equipment.
• Check that all safety decals attached to the hammer and carrier are legible. Replace
worn or illegible decals.
• Do not use drugs or alcoholic beverages that impair alertness or coordination while
operating the carrier or hammer. An operator taking prescription drugs must obtain
professional medical advice to determine if he/she can safely operate the carrier and
hammer.
• Work at a slow pace when learning to operate the hammer.
• Operator training must consist of a demonstration and verbal instruction.
• New operators must start in an area free of bystanders. He/she must become familiar
with all carrier controls before operating the hammer.
• Be aware of any prohibited uses in work areas. (Excessive slopes, poor or dangerous
terrain conditions and utility hazards.)
• Operate the carrier or hammer from the operator’s seat ONLY. Make sure the seat is
fastened securely before activating controls.
• Keep hands and feet on the controls at all times while the hammer is operating.
• Always operate the carrier with the outriggers firmly positioned on the surface.
• Make sure all controls (levers and pedals) are in NEUTRAL before starting the
carrier.
• NEVER leave the carrier with the engine running. ALWAYS ENGAGE THE
PARKING BRAKE.
• Make certain there are no persons within the arc determined by the movement of
stabilizers, front bucket or backhoe boom with the hammer at full extension.
• Never operate with any person near the hammer or between the hammer and the
operator.
• Replace all faulty or leaking hydraulic hoses or fittings before operation.
• Travel with the hammer in the full tuck (transport) position only.
• Never operate the hammer with the tool retaining pin removed.
• Wear safety goggles, hearing protection and hardhat while operating the hammer.
• Before leaving the operator’s seat, always lower the carrier boom or bucket arms.
• Stop the engine before attempting to make any repairs or adjustments to either the
carrier or the hammer.
•
ALWAYS OBSERVE ALL SAFETY INSTRUCTIONS APPLICABLE TO
YOUR CARRIER.
3
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SAFETY DECALS
The decals shown below are attached to the hammer when shipped from the factory.
Read and understand them before operating the hammer. Replace any decal that has
become worn, damaged or illegible. Decals can be ordered through the parts department.
DANGER
CAUTION
This symbol may appear on
the hammer or in the text of
this manual. It is used to alert
the operator of an action that
can place him/her or others in
a life threatening situation.
This symbol appears in the
text of this manual to identify
an action or condition that
can result in damage to the
hammer or other equipment.
4
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The notice below is included in the shipping carton. It contains information relating to
operator safety. Read and understand this notice before unpacking or operating the
hammer. We suggest you retain this notice and include it in your local safety program.
CAUTION
Never operate the hammer unless the following Safety Instructions have
been read and understood.
• Projectiles from the hammer, tool, rock or other broken material may enter
the operator’s area and cause serious or fatal injury. Use personal
protection equipment.
• Projectiles from the hammer, tool, rock or other broken material may
cause serious or fatal injury to bystanders. Do not operate the hammer
when bystanders are in the area.
• In some cases, the hammer may enter the operator’s area if a bracket or
cylinder breaks. Make sure appropriate shields are used when operating
the hammer with this type of equipment.
• Shown above is a copy of a decal that must be installed on a surface of the
hammer that faces the operator and on the carrier operator’s control area.
• Never operate the hammer if these decals are missing. Decals must be
inspected periodically to ensure that all wording is legible. Decals should
be replaced if illegible.
• Decals can be obtained at no charge from your IPC Distributor or by
contacting IPC’s Customer Service Department.
5
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2. OPERATING INSTRUCTIONS
HOW THE HAMMER OPERATES
On larger hammers the main valve is contained in the valve box, which is bolted to the
cylinder (Figure 1). During the upward stroke, the pressure in the upper chamber is
released via the main valve and through the outlet. High pressure in the lower chamber
then forces the piston upward.
As soon as the piston reaches the upper end of the stroke, the main valve directs flow to
the upper chamber causing it to become high pressure.
Since surface A is greater than surface B, the piston is driven downward with the help of
the accumulated energy from the gas chamber, creating the impact stroke of the hammer.
At the point of impact, the main valve shifts, releasing the high pressure from the upper
chamber, enabling the upward stroke to occur again.
Gas
Chamber
Valve Box
Pressure
receiving
surface A
Main Valve
Piston
Middle Chamber
Low pressure
Pressure
receiving
surface B
Lower Chamber
High pressure
Figure 1. Principle of Operation
(Refer to Table 10.)
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MOUNTING THE HAMMER TO THE CARRIER
1. Skid Steer Loader
All hammers are mounted to hammer brackets, which are then mounted to an adapter
plate using two pins. The adapter plate is mounted to the quick mount of the carrier. To
remove the hammer, first disconnect the hydraulic couplers from the inlet and outlet ports
and detach the quick mount. Seal off all plugs and hoses to prevent dust, dirt and foreign
particles from entering the system.
2. Rubber-Tired Backhoes and Excavators
All hammers are mounted to hammer brackets. The hammer brackets are mounted to the
stick of the carrier using two pins and four bushings. To remove the hammer, first
disconnect the hydraulic couplers from the inlet and outlet ports. Seal the couplers and
hoses to prevent dust, dirt, and foreign particles from entering the system. Remove the
“mounting pins” to detach hammer and bracket from the carrier stick.
CONNECTING HOSES
Connect the two hydraulic hoses to the inlet and outlet ports of the carrier using shut off
valves. When connecting, make sure that the ends are clean and engaged securely.
DAILY INSPECTION BEFORE OPERATION
1. Check the carrier hydraulic oil level before operation. The hydraulic oil level must be
correct for proper operation.
2. Check the hydraulic oil for any signs of contamination or discoloration. If any signs
of contamination appear, change the oil. (Refer to Table 2.)
NOTE: Do not mix different types of hydraulic oil.
3. Inspect all hoses and fittings for leaks or damage. Check all fasteners and tighten as
required. Replace any broken fasteners.
4. The hammer must be greased daily before use. Ten shots of grease with a grease gun
is adequate. The hammer should be greased every 2-3 hours during operation. (See
Figure 2)
5. Check the temperature of the hydraulic oil. Optimum operating temperature is 120°/
200° F (49°/93°C). The unit may not function properly and seal damage may result if
the hydraulic oil temperature goes beyond the recommended range.
Figure 2. Hammer Lubrication Point
7
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INITIAL STARTUP, HAMMER BREAK-IN
New or rebuilt hammers require 20-40 minutes of operation at half the rated speed as a
break-in period. This allows for proper lubrication of all moving parts and for all sliding
surfaces to mate properly.
GENERAL OPERATING INSTRUCTIONS
1. Never apply the tool with a side load. The tool must always be pressed firmly against,
and be perpendicular to the material to be broken. Failure to do so can cause tool or
seal failure.
2. Impact action must be stopped immediately when the object has been broken.
3. Do not pry with the tool. This may cause the tool to break or cause abnormal wear to
the tool bushings.
4. Avoid continuous impact on the same area for more than one minute. Continuous
impact may cause a rapid increase in oil temperature and improper hammer operation.
5. Break large objects from the outside edges and work inward.
6. Do not submerge the hammer in water. The hammer is not watertight, and damage
can occur if used in this manner. Consult your dealer for underwater applications
(Ref. Figure 3.)
7. Do not use the hammer to move very large or heavy broken objects. This can cause
damage to the hammer and carrier.
8. Do not use the hammer as a lifting device.
9. Do not operate the hammer when boom cylinders are at their extreme ends. This may
cause damage to the cylinders.
10. Stop operation immediately if hoses vibrate abnormally or impact energy is
dramatically reduced. Consult Section 7. “Troubleshooting Diagnosis” for additional
information.
COLD WEATHER STARTUP AND OPERATION
Note: Internal parts of the hammer will be damaged if proper warm-up procedures are
not applied in cold weather.
1. Warm the hydraulic system of the carrier before starting the hammer. Circulate the
oil in carrier system until it is warm to the touch or approximately 60°F (15°C)
2. With engine at half throttle, activate the hammer for 5 seconds and stop for 15
seconds. Repeat cycle for 2 to 3 minutes.
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UNDERWATER OPERATION
Operation of hydraulic hammers under water requires proper preparation to prevent
internal damage to hammer parts and carrier hydraulic system.
1. To prepare the hammer for underwater operation you will need
an external compressed air supply.
2. Connect air supply line to front cap threaded port (remove plug
P/N 3Z01-FP0038 as shown.) Thread is 3/8-inch pipe tapered.
3. Set pressure regulator to 50 – 90 psi.
4. Maintain air supply to hammer at all times when operating
under water
5. For HH1500 through HH8000, 20 to 50 CFM is required.
PRESSURE REGULATOR
Figure 3. Air Compressor Supply
9
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STORAGE
1. Short Term
If the hammer will not be used for periods of one week or more, the tool should be removed from
the hammer and grease must be applied to the piston bottom. The hammer should be stored
indoors standing vertically in the working position.
2. Long Term
For storage of more than 2 - 3 weeks or where condensation or corrosion is prevalent
(salt-water areas) note the following instructions. Remove and clean the tool. Flush the
front cap with clean solvent or hydraulic oil. Coat the exposed portion of the piston with
grease, apply grease to the tool and re-install. Store the hammer vertically and away
from standing moisture. To start the hammer after long-term storage, remove the tool
and inspect the exposed portion of the piston for corrosion. If corrosion is found do not
use the hammer until the defective piston has been repaired or replaced.
TOOL REPLACEMENT
Table 1. Standard Tool Weights
TOOL WEIGHTS
HH1500
Kg
45
lbs.
99
HH2000
HH3600
HH4500
HH5800
74
162
260
334
381
470
118
152
174
214
HH8000
10
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Carefully drive out the tool spring pin.
Push the tool set pin up and out of the front
cap using a screwdriver or round bar.
Note: Check Table 1, Page 10, before handling
tools.
For models HH100 through HH750-2,
manual removal is possible.
For hammer models HH1000-2 and larger
use hoist and sling as shown. Check for
sling load rating and compare to
Table 1, Page 10.
• When installing the tool in the hammer,
reverse steps 1 through 4 above. Note that
tool spring pin must be inserted with the
slot or open side away from the tool set pin.
4
SLING ANGLES
NOT SMALLER THAN:
o
60
1/3
1/3
1/3
Figure 4. Tool Replacement
11
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3. MAINTENANCE
HYDRAULIC OIL
Note: It is not recommended to mix types of hydraulic oils. Check carriers hydraulic oil
recommendations before adding hydraulic oil.
1. Check the oil level, oil filter condition and oil cooler in the carrier periodically.
2. Replace the hydraulic oil every 600 hours and the filter every 100 hours, or according
to carrier recommendations.
3. Always be aware of any abnormalities in the operation of the hammer such as
changes to hammer blow speed, impact force or oil temperature. The oil temperature
should not exceed 180°F (80°C).
4. Check the condition of the hydraulic oil as specified in Table 2.
CHECKING CONDITION OF HYDRAULIC OIL
Note: Refer to carrier service manual for proper class and type of hydraulic oil.
Hydraulic oil must be changed more frequently than the carrier instruction manual
recommends. This is because hammer operation requires more oil circulation than
normal operation. Oil condition can be visually checked as specified in Table 2.
Table 2. Hydraulic Oil Conditions
COLOR
Transparent and no color change
Transparent but too bright
Milky white
CONDITION
Good
Oil Mixed
Air and / or water mixed
Deteriorated
Dark and dirty with odor
Transparent but with black spots
Bubbly
Foreign particles mixed
Grease mixed
12
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FASTENERS
Inspect all bolts and nuts for tightness. Tighten as required. (Refer to Table 4.) Replace
all missing or damaged fasteners before operating the hammer.
Fastener bolt and nut sizes are listed in Table 3. These are wrench sizes (distance across
flats.)
Table 3. Bolt Sizes
VALVE BOX
GAS VALVE
BRACKET
BOLTS
(mm.)
SIDE
RODS
(mm.)
LIFTING
EYES
(inches)
SET
NIPPLES
(mm.)
CAP
BODY
(mm.)
*CAP
HAMMER
BOLTS
(inches)
BOLTS
(mm.)
1”
Crow
Foot
1”
Crow
Foot
1”
Crow
Foot
1”
Crow
Foot
1”
1500
36
36
46
46
46
50
50
50
60
75
75
75
54
54
63
71
85
90
¾”-10pt
*14
*17
*17
*17
*19
*19
30
30
32
32
41
41
36
36
36
36
36
36
7/8”-
9unc
2000
3600
4500
5800
8000
7/8”-
9unc
1”-8unc
1 ¼”-
8unc
Crow
Foot
1”
Crow
Foot
1 ½”-
6unc
* Allen wrench size for the front and back cap bolts.
13
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Table 4. Tightening Torque Requirements (Ft. lbs.)
HH1500 HH2000 HH3600 HH4500 HH5800 HH8000
Side Rod
880 ±35 880 ±35 1100 ±35 1850 ±75 2560 ±75 3300 ±75
Valve Box
Set Bolt
280 ±20
280 ±20
330 ±20
330 ±20
590 ±35
590 ±35
Valve Cap Bolt 175 ±20 280 ±20 330 ±20 330 ±20 480 ±35 480 ±35
Mode Valve
N/A
70 ±3
70 ±3
70 ±3
70 ±3
70 ±3
Set Bolt
Bracket Bolt
400 ±35 840 ±35 1320 ±35 2600 ±35 2600 ±35 2600 ±35
1
5
3
1
3
5
7
1
4
3
2
1
3
4
2
6
6
2
8
2
5
4
4
Side Rod
Back Nut.
&
Valve Box Set Bolt
(HH1500, HH2000,
HH3600)
Valve Box Set Bolt
(HH4500, HH5800,
HH8000)
Valve Cap Bolt
(HH2000 and up)
Mode Valve
Set Bolt
Figure 5. Tightening Sequence
GREASING REQUIREMENTS
The hammer should be greased each startup and after every 2-3 hours of operation. The
grease nipple is located at the front cap as shown in Figure 6. Approximately 10 shots in
the front cap are recommended when the tool is at the upper limit of travel.
Figure 6.
14
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NITROGEN (N2) GAS PRESSURE ADJUSTMENT
The hammer will not operate properly and may not start due to an incorrect gas charge.
Follow the procedure described below to adjust nitrogen (N2) gas pressure.
WARNING!
DO NOT STAND NEAR THE HAMMER WHEN ADDING NITRIGEN. THE
TOOL MAY EJECT SUDDENLY AND CAUSE SEVERE INJURY.
1. Gas Pressure Testing.
a. With the gas charger disconnected from the hammer, plug the inlet (the nitrogen
hose connection port) of the gas charger with the cap provided, then turn the
“T” handle fully to the left (counter clockwise.)
b. Remove the gas valve cap located on the hammer back cap and attach gas charger,
see Figure 7.
Figure 7. Connecting Gas Charger to
Hammer
Figure 8. Connecting Gas Charger to
Nitrogen (N2) Supply
c. Turn the “T” handle on the gas charger valve clockwise, and then measure the N2
gas pressure.
2. Releasing Gas Pressure (if over charged or prior to disassembly)
a. Test the gas pressure as described in paragraph 1.
b. For disassembly loosen the bleeder screw on the gas charger very slowly and
release the N2 gas. Watch the pressure gauge until the nitrogen pressure is fully
released. (see Figure 7 and 8.)
c. If overcharged close the Bleeder Screw when the gas pressure reaches the correct
gas pressure shown on Table 10, Page 26, then turn the “T” handle to the left
(counter clockwise).
d. Finally, remove the gas charger. Install and tighten the gas valve cap.
3. Refilling Nitrogen (N2) Gas
a. Perform paragraph 2 procedure.
b. Remove the cap on the gas charger, nitrogen hose connection port. See Fig 9.
c. Attach the N2 gas pressure regulator to the gas container. Connect the nitrogen
(N2) Supply tank to the gas charger with the charging kit hose.
15
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Figure 9. Gas Charger Valve
d. Open the main gas valve on the N2 gas container and regulate the N2 gas pressure
(see Figure 8.)
e. Turn the gas charger “T” handle clockwise and adjust N2 gas pressure in the gas
chamber to the correct gas pressure shown on Table 10, Page 26.
f. Turn the gas charger “T” handle fully counter clockwise and remove the hose.
Attach the cap to the gas inlet of the charger.
g. Remove the gas charger and attach the gas valve cap and O ring firmly to the gas
valve nut on the hammer back cap.
OIL LEAKAGE INSPECTION
Check for oil leakage at the points shown in Table 5. It is not unusual to have a small
amount of oil leakage along the tool or cylinder, (refer to Figure 10.)
Table 5. Diagnosis of Oil Leakage
LEAK LOCATION
POSSIBLE CAUSE
REMEDY
Between front cap
and tool (E)
Damaged or worn
U-packing
Replace seal kit
Between cylinder and
nipple (F)
Loose nipple or damaged
O-ring or nipple
Tighten or replace nipple,
and / or O-ring
Damaged U-packing or
main
Valve outer sleeve O-ring,
or
Between cylinder and
back cap (G)
Replace seal kit
Back cap O-ring
Remove plugs and reinstall
with sealant
Plug ports (H)
Plugs loosen
16
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Figure 10.
GAS LEAKAGE INSPECTION
Gas leakage can be easily detected using soapy water (refer to Table 6 and Figure 11.)
Table 6. Diagnosis of Gas Leakage
LEAK LOCATION
POSSIBLE CAUSE
REMEDY
Gas valve assembly (A) or
Between gas valve assembly damaged
and back cap (B)
Between back cap and
cylinder (C)
Defective O-ring,
Replace gas valve
assembly
Spring or gas valve
Defective back cap O-ring Replace back cap O-ring
Figure 11
17
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4. DISASSEMBLY AND ASSEMBLY
DISASSEMBLY
1. Tool
Refer to tool replacement procedures on Figure 4, page 11.
2. Back cap
Support the cylinder (Figure 12). Loosen and remove four side rods and washers,
then remove the back cap.
3. Front cap (See Table 3 page 13 for eyebolt sizes)
Install an eyebolt and suspend the front cap as shown in Figure 12. Pull out the front
cap, being careful not to damage the piston.
Figure 12. Connecting Hoist to Front Cap.
18
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4. Main Valve Box Assembly
Service of the Valve Box includes the Mode Valve Assembly and the Main Valve
with Box Sleeve.
a. Remove six or eight (depending on hammer model) Valve Box (4) Set Bolts and
place Valve Box on a clean flat service.
Note: Inspect o-rings located at ports on cylinder and replace o-rings as
necessary. When re-installing Valve Box check that all o-rings are
in correct position.
b. Remove four Mode Valve (1) Set Bolts and replace o-ring seals as necessary.
c. Remove ten socket head cap screws and the Upper Valve Cap (3) and Lower
Valve Cap (7).
d. Remove the Box Sleeve (6) and the Main Valve (5) from the Lower Valve bore
and inspect for scoring or wear.
Note: Minor scratches can be polished by hand using the same procedure
as the piston and cylinders. Ref. Para. 6 page 27. Main Valve (5)
and Box Sleeve (6) must be capable of free movement by hand
without sticking or dragging. If not satisfactory replace with new
parts.
e. Reassemble by reversing above procedure.
Note: Keep work area clean and lubricate all parts with clean hydraulic
oil during assembly.
f. Torque bolts to proper specifications and sequence shown on Table 4 and figure 5
on page 14.
Figure 13. Main Valve Box Assembly
19
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5. Piston (See Table 7 for Piston weights)
Note: For large hammers, you may wish to stand the hammer upright
with proper support, and pull the piston upward using a lifting device.
a. Attach an eye bolt to the top of the piston and pull out together with cylinder
sleeve toward the top.
b. It may be useful to use a pry bar as a lever as shown in Figure 14. Be careful to
not damage the piston.
Figure 14. Removing the piston.
5. Cylinder sleeve
Note: Support piston on wood blocks.
Remove the cylinder sleeve from the piston. A plastic hammer or nylon bar can be used
for removal as shown in Figure 15. Do not force the cylinder sleeve. Tap uniformly on
all sides of the sleeve.
Figure 15. Removing Cylinder Sleeve
Table. 7. Piston Weights
WEIGHTS
HAMMER MODEL
kg
41
64
101
122
153
198
lbs.
90
HH1500
HH2000
HH3600
HH4500
HH5800
HH8000
142
222
270
338
436
20
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INSPECTION OF PARTS
1. Seals
Seals that are deformed, scratched, worn or aged should be replaced (see Figure 16).
It is recommended that all seals be replaced when disassembling the hammer.
Figure 16. Seal Conditions
2. Moving parts
Check for any scratches or damage on the surface of the piston, cylinder sleeves, main
valve and bottom part of the piston where it strikes the tool. Significantly damaged or
scratched parts must be replaced.
3. Front cap
a. Deformed or worn shank bushings or front cap bushings must be replaced, see
Table 8 page 23.
b. A severely worn or damaged tool set pin must be replaced.
4. Replacing the front cap bushing
a. Measure shank and front cap bushings and refer to Table 8 page 23 and Table 9
page 24.
b. Remove bushing set pin and bushing spring pin using a hammer and drive pin.
c. The front cap bushing must be torch cut at three locations (at three 120° grooves)
if it is the only bushing to be replaced. Avoid cutting into the front cap itself.
d. Any scratches in the front cap must be smoothed after bushing removal.
e. Install the new front cap bushing in the correct direction with part numbers on the
bushing facing the installer (away from the hammer.) Because the bushings are a
press, or interference fit, heating of the front cap and cooling of the bushing will
help installation.
f. Insert the bushing set pin and the bushing spring pin.
BE CAREFUL OF HOT SURFACE. USE GLOVES TO PROTECT
AGAINST BURNS AND POSSIBLE SHARP EDGES.
21
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5. Replacing the shank bushing
Note: Replacement of the front cap bushing is required when replacing the shank
bushing, as the front cap bushing must be removed to replace the shank bushing.
a. Measure the shank and front cap bushing; refer to Table 8 page 23 and Table 9
page 24.
b. Remove bushing spring pin and bushing set pin for shank bushing on the front cap
using a punch and hammer.
c. Press out shank bushing from the cylinder side together with front cap bushing
using a round bar. If the shank bushing is too tight, cutting it with a torch may be
required.
d. Any scratches on the front cap during the cutting operation must be smoothed out
using a hand grinder.
e. Install a new shank bushing after greasing. As bushings are a press, or
interference fit, heating of the front cap or cooling of the bushing will ease
installation of the bushing.
f. Install the bushing set pin and the bushing spring pin.
6. Refinishing surface scratches (see Section 6. Page 27)
a. Cylinder and Cylinder Sleeve
Scratches on the inside surface of the cylinder should be smoothed using a flap wheel
with 240 grit and finish with 360 grit.
b. Piston
Grind off any scratches on the outside surface using a flap wheel with 240 grit and
finish with 360 grit. When polishing the piston or the cylinder bore, it is not necessary
to completely remove scratches (only the sharp edges) as this may remove excess
material. (See Figures 19, 20 and 21 on page 27.)
c. Main Valve and Sleeves
Main valve and sleeves cannot be polished. Replace if these parts do not slide freely
by finger pressure.
22
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COMPONENT WEAR LIMITS
Parts are to be replaced if not within the wear parameters. See Table 8 and Figure 17
below, for new dimensions see Table 9 page 24.
Table 8. Component Wear Limits
COMPONENT
WEAR LIMITS
When the clearance between the tool and the front cap bushing
exceeds .300 in. (8mm), a new front cap bushing is required.
(Approximately 500 hours of use).
Front cap
bushing
When the clearance between the tool and the shank bushing
Shank bushing exceeds .160 in. (4mm), a new shank bushing is required.
(Approximately 700 hours of use).
If .120 in. (3mm) of wear in the diameter is observed, a new tool is
required. (Approximately 500 hours of use). Keep tool sharp.
Tool
If .080 in. (2mm) of wear in the diameter is observed, a new tool set
pin is required.
Tool set pin
If the corner of the front cap is worn to the edge of the front cap
bushing, a new front cap is required.
Front cap
When indentation or serious damage on the piston surface is
Piston
observed, a new piston is required. (Approximately 2,000 hours of
use).
Figure 17. Wear Limit Points
23
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Table 9. New Component Dimensions
PART
HH1500 HH2000 HH3600 HH4500 HH5800 HH8000
101. mm. 116. mm. 136. mm. 146. mm 156. mm 166. mm
3.967 in. 4.567 in. 5.354 in. 5.748 in. 6.142 in. 6.535 in.
101. mm. 116. mm. 136. mm. 146. mm. 156. mm 166. mm
3.967 in. 4.567 in. 5.354 in. 5.748 in. 6.142 in. 6.535 in.
100. mm. 115. mm. 135. mm. 145. mm. 155. mm 165. mm
3.937 in. 4.528 in. 5.315 in. 5.709 in. 6.102 in. 6.496 in.
Front Cap Bushing I.D.
Shank Bushing
Tool
I.D.
O.D.
ASSEMBLY
Note: Clean every part before assembly. Keep parts clean and do not scratch during
assembly. Assembly can basically be done in the reverse order of disassembly. Make
sure parts are installed in the correct direction.
1. Lubricate the U-packing, O-ring, piston, cylinder and main valve with hydraulic oil
before assembly.
2. Place cylinder sleeve on the piston.
3. Insert the piston fully into the cylinder to its bottom position.
a. Make sure that all seals are positioned correctly and facing the right direction.
b. Handle seals very carefully in order not to cause scratches.
c. To avoid scratching the piston, the cylinder sleeve can be installed with a plastic
hammer or nylon bar.
4. Install the front cap on the cylinder.
5. Insert the main valve and the outer sleeve.
6. Apply hydraulic oil into the back cap for gas seal lubrication. See Figure 18.
7. Attach the back cap to the cylinder.
HH1500
HH2000
HH3600
HH4500
HH5800
HH8000
1.0 oz. or 30 cc.
3.5 oz. or 100 cc.
5.0 oz. or 150. cc.
5.0 oz. or 150. cc.
5.0 oz. or 150. cc.
6.0 oz. or 180. cc.
Figure 18. Adding oil to the Back Cap.
24
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8. Insert and tighten the four side rods together with the washer to the specified torque
(see Table 4 and Figure 5 on page 14.)
9. Refill the hammer with Nitrogen (N2) gas. Refer to pages 15 and 16.
Make sure that the piston is positioned at the lower end of its stroke before charging. The
piston and the cylinder may be damaged during gas charging by sudden movement (due
to a pressure increase) if the piston is not at the bottom of its stroke in the cylinder.
25
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5.
SPECIFICATIONS
Table 10. Specifications
ITEM
UNIT
HH1500
HH2000
HH3600
HH4500
HH5800
HH8000
ft-lbs.
kg-m
Impact energy
1500
2000
3600
4500
5800
8000
450-560
345-430
340-450
280-370
Blows per
minute
400-650
300-500
480-630
380-500
480-625
350-450
bpm
480-550
50-63
189-238
62-73
234-276
Required
oil flow
gpm
l/min
21.3-28.7
80-108
21.3-36.7
80-138
36-55
136-207
40-56
151-211
2430-2710 2430-2710
Operating
pressure
psi
bar
2000-2290 2000-2290 2290-2570 2430-2710
140-160
140-160
160-180
170-190
170-190
170-190
160-185
11-13
160-185
11-13
Nitrogen
gas pressure
psi
bar
140-160
10-11
140-175
10-12
160-185
11-13
160-185
11-13
5400
2455
6800
3091
Total weight
with tool
lbs.
kg
1400
636
2100
955
3200
1455
4200
1909
105
266
inch
mm
70
176
78
199
90
228
98
250
116
294
Total length
6.1
155
6.5
165
inch
mm
4.0
100
4.5
115
5.3
135
5.7
140
Tool diameter
55000-
90000
24950-
40820
70000-
130000
31750-
58970
36000-
58000
16330-
26310
41000-
70000
18600-
31750
18000-
30000
8200-13700 9070-18140
20000-
40000
Applicable
carrier
lbs.
kg
2980-3550 2980-3550
210-250 210-250
Carrier Relief
Valve Setting
Psi
Bar
2600-2900 2600-2900 2900-3300 2980-3550
180-200 180-200 200-230 210-250
Remarks:
• The hammer is to be used within the specified oil pressure, oil flow and gas pressure
parameters.
• The carrier hydraulic system relief pressure is to be set at 600 to 800 psi above the
hammer “Operating Pressure.”
• Hydraulic pressure is to be measured at the hose end of the carrier (output or pressure
hose) when disconnected from the hammer.
26
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6. REFINISHING OF PISTONS & CYLINDERS
If the pistons and cylinders should be scored or scratched due to dirty oil, or improper
hydraulic oil specifications, the piston and cylinder can in many cases be polished and
salvaged, instead of being replaced.
This is possible because the components in this hammer are made of high quality alloy
steel and do not use chromium surface finishes which cannot be polished.
Follow the procedures in Figures 19, 20 & 21 and finish by thorough flushing and
cleaning. These parts can usually be salvaged.
Caution: Wear safety glasses for eye protection
Use hand held air grinder with flap type wheels.
Two grit wheels were used:
#240 for Heavy Polish.
#360 for Finishing.
Figure 19.
Rotate piston and polish with brushing motion of
grinder.
Polish total area before changing to fine grit for
finishing.
Figure 20.
After completion of fine polishing, clean labyrinth
grooves carefully with fine needle file to remove all
burrs and rough edges.
Figure 21.
After polishing all rough surfaces and edges, clean all parts by flushing thoroughly.
Lubricate with hydraulic oil before reassembling.
Note: It is not necessary to completely remove all scoring or scratching to full depth of
the scratches. Instead polish the surfaces until any raised edges are flush and smooth
with the original surface. If this procedure is followed excess material will not be
removed and normal tolerances can be maintained inside the hammer.
27
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7. TROUBLESHOOTING DIAGNOSIS
Table 11. Troubleshooting
SYMPTOM
Hammer
POSSIBLE CAUSE
Couplers are not engaged
REMEDY
Connect couplers securely
does not run
Adjust main and secondary relief
valve
Relief valve set incorrectly
Malfunction of the hydraulic pump Repair pump
Nitrogen gas pressure is too high
Main valve is damaged
Adjust gas pressure
Replace main valve
Piston is damaged
Couplers are not fully engaged
Repair or replace piston
Connect couplers securely
Hesitation or
erratic
operation
Adjust main and secondary relief
valve
Relief valve set incorrectly
Malfunction of the hydraulic pump Repair pump
Oil temperature is too high
(exceeds 180°F or 80°C)
Check oil cooler
Main valve is damaged
Replace damaged main valve
Decreased oil flow
Avoid simultaneous axis movement
Auto shut-off in operation, tool is
suspended
Apply proper down force
Excessive bushing wear
Piston is damaged
Nitrogen pressure is too high
Replace worn bushings
Repair or replace piston
Adjust gas pressure
Slow impact
speed
Hydraulic oil leakage into the gas
chamber
Replace seal kit
Malfunction of the hydraulic pump Repair pump
Deteriorated or contaminated oil
Nitrogen gas pressure is low
Change oil
Low impact
power
Adjust gas pressure
Adjust main and secondary relief
valve
Relief valve set incorrectly
Malfunction of the hydraulic pump Repair pump
28
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8. WARRANTY GUIDE LINES
Time based on total man-hours.
Seal kit installation (Includes testing, complete disassembly, cleaning and re-assembly)
HH100 - HH1000 = 4 hours
HH1500 - HH2000 = 6hours
HH3600 - HH4500 = 7hours
HH5800 – HH8000 = 8hours
Front cap bushing (Includes removal and re-installation, hammer disassembly not
required)
HH150 - HH1000 ½ hour
HH1500 - HH8000 1 hour
Shank bushing (Includes complete disassembly, removal of both bushing and re-
assembly)
HH150 - HH1000 = 3 hours
HH1500 - HH2000 = 4 hours
HH3600 – HH8000 = 5 hours
Side rod replacement only (Includes complete disassembly, removal of broken side rod
and re-assembly)
HH150 - HH1000 = 2 hours
HH1500 - HH2000 = 3 hours
HH3600 - HH8000 = 4 hours
Bracket bolt replacement
HH100 - HH1000 = ¼ hour
HH1500 - HH8000 = ½ hour
29
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IPC Industries, Inc.
194 N. Brandon Dr.
Glendale Heights, IL 60139
LIMITED WARRANTY FOR HYDRAULIC HAMMERS
LIMITED WARRANTY
The manufacturer warrants its Products against defects in material and workmanship. Such LIMITED
warranty shall apply to the initial Purchaser only. The BACK-CAP, MAIN BODY and FRONT CAP carry
a LIFETIME, UNLIMITED HOURS warranty. All other components (except seals and exclusions listed
below) are warranted as follows: THREE (3) YEARS, UNLIMITED HOURS. Seals are warranted for a
period of TWO (2) YEARS, UNLIMITED HOURS. All Warrantees begin from the date of sale to the
original retail end-user or the initial rental service of the hammer.
ITEMS EXCLUDED FROM THIS WARRANTY
Normal wear items such as tools (moil, chisel, blunt, tamper, frost wedge and asphalt cutter), shank
bushings, tool bushings, set pins, hoses, hose adapters and accessories are specifically excluded from
any and all warrantees.
WARRANTY LIMITATIONS
This warranty will be in effect only if:
1. The Purchaser or his agent has the Product installed and operating in accordance with the published
Manufacturers specifications and guidelines.
2. The Purchaser or his agent does not exceed the Products published design operating range for
hydraulic flow, pressure or recommended carrier size.
3. The Purchaser or his agent complies with the maintenance schedule in the Operating and Service
Manual supplied with each Product.
4. The Purchaser or his agent uses replacement parts/products received from or approved by IPC
Industries, Inc.
This Warranty will not cover defects/failures caused by abuse, neglect, misuse, lack of maintenance,
accident or use of the Product beyond its published design capacity, specifications or recommended
applications.
The Manufacturer will authorize the return of defective components to the Manufacturers warehouse or
location specified by the Manufacturer. The Manufacturer will determine if said components show clear
and evident proof of defective material and/or workmanship. A warranty claim will only be accepted
if accompanied by proof of purchase and received within thirty-(30)-days of the warranted defect
or failure.
The Manufacturer will, at its option, determine what, if any, defective/faulty components will be accepted
for warranty coverage. The Manufacturer will, at its option, determine whether to repair or replace
components deemed faulty because of defective materials or workmanship. The manufacturer will not
be accountable for mileage, travel time, travel costs, and/or any freight costs incurred to facilitate the
needed replacement or repairs beyond those stated within the document (attached) titled “Warranty
Policy Statement”. The Manufacturer shall not be liable for lost rental income, machine availability or
failure of components not supplied or installed by Manufacturer.
WARRANTY DISCLAIMER
This Warranty is exclusive and in lieu of all other representations and warranties, expressed or implied. The Manufacturer
expressly disclaims and excludes any implied warranty of merchantability or fitness for a particular purpose. In no event shall
the Purchaser or his agent be entitled to any consequential damages of any kind, whether arising out of breach of contract,
warranty (including negligence and strict liability) or other theories of law, with respect to products sold or services rendered
by the Manufacturer, or any undertakings, acts or omissions relating thereto. The Manufacturer reserves the right to change
these policies as conditions dictate.
July 1, 2005
30
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Warranty Policy Statement
This document explains IPC Industries, Inc. specific policies concerning submission and
reconciliation of warranty claims. This document is in addition to and a part of the IPC
Industries, Inc. Limited Lifetime Warranty For Hydraulic Hammers that accompanies all
new hydraulic hammer products.
1. Warranty Registration Card
Each hydraulic hammer is shipped with a Warranty Registration Card. In order to
properly process your claim this card must be on file at IPC. This card not only
registers the product for warranty purposes it keeps IPC informed so we can contact
you concerning product updates, parts specials and service bulletins.
2. Ordering Warranty Replacement Parts
All parts ordered from IPC will, without exception, be invoiced and shipped freight
collect or prepaid with freight on the invoice. Warranted costs for freight will be
resolved on the Warranty Claim form you will be returning with the defective part.
3. Filing a Claim
Every IPC product shipped includes two service manuals and a package containing a
Warranty Claim form and a Delivery Report form for pre-delivery. The Warranty
Claim form is located in the envelope labeled ”Distributor Information”.
4. Labor Reimbursement and Using the Warranty Claim Form
Fill out all items as completely as possible. Take note of (5.) below. In the section
titled “DESCRIPTION OF FAILURE” describe the failure as clearly as possible along with
operating conditions of the hammer and carrier as best you can.
In order for IPC to consider “DEALER LABOR” and “DEALER MILEAGE” in your claim,
your published labor and mileage rates must be on file with IPC or must accompany
the claim form. Please see (8.) below for an explanation of “FREIGHT (PAID)”.
In no event shall IPC Industries, Inc. warrant more than one (1) hour travel time
(each way) or eight (8) hours of labor for a hammer repair.
Please refer to the service manual for easy to follow disassembly and assembly
procedures. IPC Industries, Inc. would be pleased to provide you with no-charge
“on-site” service training covering all aspects of hammer service.
5. Warranty Submission Time Limit
No more than thirty- (30)-days can elapse between the “DATE OF FAILURE” and
“DATE OF CLAIM”. Claims submitted beyond thirty- (30)-days from the “DATE OF
FAILURE” will be denied.
IPC’s purpose is to provide the best possible product reliability and customer service.
Our best sources for product reliability information and failure analysis are used/failed
parts from the field. A part that has been exposed to weeks of weather tells us little or
nothing. If we can’t tell why or where a part failed because of rust or damage we can’t
warranty the part.
31
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6. Requesting a Returned Goods Authorization (RGA)
Before returning a suspected warranty part, call IPC at (800) 487-5431 and our customer
service representatives will provide you with a RGA number. Please have the description
of the part(s) at hand and the method by which you will be returning the part prepaid to
IPC. At that time it may be determined that you need not return the part and IPC may, at
its sole discretion, warrant the part without examination. Do not scrap any parts under
warranty consideration unless authorized by IPC or credit is received.
7. Returning a Warranted Part
All returned parts must be shipped prepaid (not collect) and include the RGA number
prominently displayed on the shipping label. If a part is particularly heavy, please
contact us for further information.
8. Warranty Part Freight Costs
IPC Industries, Inc. will cover inbound (when requested by IPC) and outbound freight
for warranted parts under the following circumstances only:
• IPC will cover surface freight costs for parts judged to be defective in materials
or workmanship.
• The cost of shipping warranted parts via an expedited surface or air shipment will
be paid as follows: IPC will pay the difference between standard surface freight
and air or expedited surface freight, whichever is less.
9. IPC Claims Processing
IPC will respond to the dealer submitting the claim within 30 days as follows:
• A credit for an approved claim which contains the required information or,
• A request for further information, for return of the parts for analysis (refer to 6.
and 7. above)
or,
• Notification of a denied claim with an explanation of why the claim was denied.
32
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9. PARTS LIST AND ILLUSTRATIONS
HH1500
HH2000
HH3600
HH4500
HH5800
HH8000
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HH1500 HAMMER
ITEM
NAME
NUMBER
3J01-212001
Seal Kit
Seal Kit
Seal Kit
QTY.
1
2
3
4
Cylinder
1
2
2
1
Cylinder O-Ring*
Cylinder O-Ring*
Cylinder O-Ring*
5
6
7
Cylinder Sleeve
Cylinder Sleeve O-Ring*
Quad Ring*
3J01-212002
Seal Kit
Seal Kit
1
2
1
8
9
Back Up Ring*
Step Seal*
Seal Kit
Seal Kit
1
1
10
11
12
13
14
15
16
17
18
19
20
21
22
23
24
25
26
27
28
29
30
31
32
33
34
35
36
37
38
39
40
41
42
43
44
45
46
NI
NI
47
48
Step Seal O-Ring*
U-Packing*
Dust Seal*
Seal Kit
Seal Kit
Seal Kit
1
2
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
4
6
1
1
1
1
1
1
3
6
2
2
4
4
4
Drain Plug
3Z01-DP0014
3J01-2120095
3Z01-21209040B
3J01-2120081
3Z01-21209056W
3J01-2120082
3Z01-21209040B
3J01-2120011
3J01-2120021
3F01-2100622
3E01-2060623
3E01-2060624
3E01-09092B
3J01-2120023
3J01-C4009B
3H01-B48138
3J01-2120031
Seal Kit
3J01-2120041
3Z01-FP0038
3J01-2120042
3J01-2120043
3J01-2120044
3H01-S40108
3F03-N00002
Ass’y of item 37
3J01-2120051
Ass’y of item 39
Ass’y of item 39
Ass’y of item 39
3Z01-GN0018
3J01-2120061
3H01-S40248
3J01-212P(Fx, E)
3J01-212SK
3Z01-202GC
3Z01-G00001
3Z01-G00004
Choke Plug #1
Choke O-Ring*
Plug
Plug O-Ring*
Choke Plug #2
Plug O-Ring*
Piston
Valve Box
Main Valve
Main Valve Inner Sleeve
Main Valve Outer Sleeve
Main Valve O-Ring*
Valve Cap
Valve Cap Bolt
Valve Box Set Bolt
Back Cap
Back Cap O-Ring*
Front Cap
Front Cap Plug
Shank Bushing
Front Cap Bushing
Bushing Set Pin
Bushing Spring Pin
Nipple PF—3/4in.—1.1/16in. UN
O-Ring 1BG-30
Side Rod Assembly
Side Rod Front Nut
Side Rod Back Nut
Side Rod Washer
Grease Nipple
4
1
1
2
1
1
1
1
Tool Set Pin
Tool Spring Pin
Tool Moil (Chisel, Blunt)
Seal Kit
Gas Charger
Gas Valve Assembly (Includes item # 48)
Gas Valve Cap with O-Ring
1
*Included in seal kit.
NI denotes not illustrated.
Effective 07/05
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HH1500 HAMMER
Effective 07/05
35
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HH1500 HAMMER
BRACKET ASSEMBLY PARTS LIST
PART NO.
MODEL HH1500
3J01-212501
-----------------
3H01-215502
Assembly of Item 3
Assembly of Item 3
3J01-212504
3H01-TC2000B
Assembly of item 7
Assembly of item 7
Per Carrier Model
ITEM
QTY
DESCRIPTION
1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
1
1
4
4
8
Hammer Bracket (R)*
Hammer Bracket (L)*
Bracket Bolt
Washer
Nut
2
Support Pipe
Top Cap Bolt
Top Cap Washer
Top Cap Nut
Top Cap
10
10
10
1
*Sold as matched set w/ hardware
Effective 07/05
Prices subject to change without notice.
36
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HH2000 HAMMER UP TO S/N 2K031
SOLD BEFORE 9/96
ITEM
NAME
NUMBER
QTY.
1
Cylinder
3H01-2150001
3H01-09098B
3H01-09072B
3H01-2150002
3H01-09288W
3H01-U15000G
3H01-U15000I
3H01-15000H
3H01-15000D
3Z01-DP0014
3H01-2150011
3H01-2150021
3H01-2150022
3H01-2150023
3H01-07108B
3H01-08108G
3H01-051180
3H01-2150025
3Z01-PN0510
3H01-2150026
3H01-07118B
3H01-08118G
3H01-B48138
3H01-B44098
3H01-09040B
3H01-21580031
3H01-07358A
3H01-2150041
3Z01-FP0038
3H01-150042
3H01-150043
3H01-150044
3H01-S40108
3Z03-N00002
3Z03-07068B
3H01-150051
3H01-150052
3H01-150053
3H01-150054
3Z01-GN0018
3H01-150061
3H01-S40248
3H01-215P(Fx, E)
3H01-2210027
3H01-2210028
3H01-09044W
3H01-09036W
3H01-B32068
3H01-B24040
3H01-SW0008
3H01-PN0308
3H01-SL10018
3H01-215SK
1
2
3
1
3
1
2
2
1
1
1
1
1
1
1
1
1
1
1
1
1
1
6
10
2
1
1
1
1
1
1
3
6
2
2
4
4
4
4
1
1
2
1
1
1
1
1
4
1
1
3
1
1
1
1
1
1
1
2
3
4
5
6
7
8
9
Cylinder O-Ring*
Cylinder O-Ring*
Cylinder Sleeve
Cylinder Sleeve O-Ring*
Gas U-Packing*
U-Packing*
U-Packing with Back Up Ring*
Dust Seal*
10
11
12
13
14
15
16
17
18
19
20
21
22
23
24
25
26
27
28
29
30
31
32
33
34
35
36
37
38
39
40
41
42
43
44
45
46
47
48
49
50
51
52
NI
NI
NI
NI
53
54
Drain Plug
Piston
Valve Box
Main Valve
Upper Valve Cap
Valve Cap O-Ring*
Back Up Ring*
Valve Cap O-Ring*
Lower Valve Cap
Locater Pin
Box Sleeve
O-Ring*
Back Up Ring*
Valve Box Set Bolt
Valve Cap Bolt
Valve Box O-Ring*
Back Cap
Back Cap O-Ring*
Front Cap
Front Cap Plug
Shank Bushing
Front Cap Bushing
Bushing Set Pin
Bushing Spring Pin
Nipple PF—3/4in.—1.1/16in. UN
O-Ring 1BG-30
Side Rod Assembly
Side Rod Front Nut
Side Rod Back Nut
Side Rod Washer
Grease Nipple
Tool Set Pin
Tool Spring Pin
Tool Moil (Chisel, Blunt)
Mode Valve Body
Mode Valve
Mode Valve O-Ring*
Mode Valve O-Ring*
Mode Valve Set Bolt
Mode Valve Lock Bolt
Spring Washer
Locater Pin
Stop Ring
Seal Kit
Gas Charger
3Z01-202GC
3H01-221MVA
3H01-215VBA
3Z01-G00001
3Z01-G00004
Mode Valve Assembly
Valve Box Assembly
Gas Valve Assembly (Includes item # 54)
Gas Valve Cap with O-Ring
*Included in seal kit only.
NI denotes not illustrated.
Effective 07/05
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HH2000 HAMMER UP TO S/N 2K031
SOLD BEFORE 9/96
Effective 07/05
39
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HH2000 HAMMER S/N 3K001 & UP
SOLD AFTER 10/96
ITEM
NAME
NUMBER
3H01-2150001
3H01-09098B
3H01-09072B
3J01-2210081
3J01-09056W
3H01-08056P
3H01-2150002
3H01-09288W
3H01-QD215000
3H01-BU215000
3H01-ST215000
3H01-OR215000
3H01-U15000I
3H01-15000H
3H01-15000D
3H01-2150011
3H01-2150021
3H01-2150022
3H01-2150023
3H01-07108B
3H01-08108G
3H01-051180
3H01-2150025
3Z01-PN0510
3H01-2150026
3H01-07118B
3H01-08118G
3H01-B44098
3H01-B48138
3H01-2210027
3H01-2210028
3H01-09044W
3H01-09036W
3H01-B32068
3H01-B24040
3H01-SW0008
3Z01-PN0510
3H01-SL0018
3H01-09040B
3H01-21580031
3H01-07358A
3Z01-G00001
3Z01-G00004
3H01-2150041
3Z01-FP0038
3H01-150042
3H01-150043
3H01-150044
3H01-S40108
3Z03-N00002
3Z03-07068B
3H01-150051
3H01-150052
3H01-150053
3H01-150054
3Z01-GN0018
3H01-150061
3H01-S40248
3H01-215P(Fx, E)
3H01-215SKX
3Z01-202GC
QTY.
1
Cylinder
1
2
3
5
10
5
1
2
1
1
2
2
1
1
1
1
1
1
1
1
1
1
1
1
1
2
1
10
6
1
1
1
1
4
1
1
3
1
2
1
1
1
1
1
1
1
1
3
6
2
2
4
4
4
4
1
1
1
1
1
1
1
1
2
3
4
5
6
7
8
9
Cylinder O-Ring*
Cylinder O-Ring*
Plug
Cylinder O-Ring*
Buffer Ring*
Cylinder Sleeve
Cylinder Sleeve O-Ring*
Quad Ring*
Back Up Ring*
Step Seal*
Step Seal O-Ring*
U-Packing*
U-Packing*
Dust Seal*
Piston
10
11
12
13
14
15
16
17
18
19
20
21
22
23
24
25
26
27
28
29
30
31
32
33
34
35
36
37
38
39
40
41
42
43
44
45
46
47
48
49
50
51
52
53
54
55
56
57
58
59
NI
NI
NI
NI
Valve Box
Main Valve
Upper Valve Cap
Valve Cap O-Ring*
Back Up Ring*
Valve Cap O-Ring*
Lower Valve Cap
Locater Pin
Box Sleeve
Box Sleeve O-Ring*
Back Up Ring*
Valve Cap Bolt
Valve Box Set Bolt
Mode Valve Body
Mode Valve
Mode Valve O-Ring*
Mode Valve O-Ring*
Mode Valve Set Bolt
Mode Valve Lock Bolt
Spring Washer
Locater Pin
Stop Ring
Valve Box O-Ring*
Back Cap
Back Cap O-Ring*
Gas Valve Assembly (Includes item # 43)
Gas Valve Cap with O-Ring
Front Cap
Front Cap Plug
Shank Bushing
Front Bushing
Bushing Set Pin
Bushing Spring Pin
Nipple PF—3/4in.—1.1/16in. UN
O-Ring 1BG-30
Side Rod Assembly
Side Rod Front Nut
Side Rod Back Nut
Side Rod Washer
Grease Nipple
Tool Set Pin
Tool Spring Pin
Tool Moil (Chisel, Blunt)
Seal Kit
Gas Charger
Mode Valve Assembly
Valve Box Assembly
3H01-221MVA
3H01-215VBA
*Included in seal kit only.
NI denotes not illustrated.
Effective 07/05
40
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HH2000 HAMMER S/N 3K001 & UP
SOLD AFTER 10/96
Effective 07/05
41
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HH2000 HAMMER
BRACKET ASSEMBLY PARTS LIST
PART NO.
MODEL HH2000
3H01-215501
-----------------
3H01-215502
ITEM
QTY
DESCRIPTION
1.
2.
3.
1
1
6
Hammer Bracket (R)*
Hammer Bracket (L)*
Bracket Bolt
4.
5.
NI
6.
NI
7.
8.
9.
10.
11.
12.
Assembly of Item 3
Assembly of Item 3
3H01-215504-198
3H01-215505-262
3H01-215506-162
3H01-TC2000B
Assembly of Item 8
Assembly of Item 8
3H01-215505
6
12
2
2
2
10
10
10
4
4
1
Washer
Nut
Support Pipe (Top)
Support Pipe (Middle)
Support Pipe (Bottom)
Top Cap Bolt
Top Cap Washer
Top Cap Nut
Cushion Rubber
Screw
Assembly of Item 10
Per Carrier Model
Top Cap
*Sold as matched set w/ hardware. NI denotes not illustrated.
Prices subject to change without notice.
Effective 07/05
42
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43
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HH3600-2 HAMMER
S/N 5M1000 & UP
ITEM
NAME
NUMBER
QTY.
1
Cylinder
3J01-B2210001-2
3J01-09108B
3H01-09072B
3J01-2210002-2
3J01-07328W
3J01-170561
3J01-QD221000
3J01-170563
3J01-U21000I
3J01-D21000D
3J01-2210011-2
3J01-2210021-2
3J01-2210022-2
3J01-2210023
3H01-07118B
3H01-08118G
3J01-051280
3J01-2210025-2
3Z01-PN0510
3J01-2210026-2
3J01-07128B
3J01-08128G
3J01-B52146
3J01-B52128
3H01-09040B
3J01-2210031
3J01-07398A
3J01-240081
3J01-09076W
3J01-08076P
3J01-2212095
3J01-09056W
3J01-2210041-2
3Z01-FP0038
3J01-2210042
3J01-210043
3J01-210044
3J01-S46128
3J01-N00003
3J01-07078B
3J01-210051
3J01-210052
3J01-210053
3J01-210054
3Z01-GN0018
3J01-221091
3J01-S46128
3J01-210061
3J01-221P(Fx, E)
3H01-2210027
3H01-2210028
3H01-09044W
3H01-09036W
3H01-B32068
3H01-B24040
3H01-SW0008
3H01-PN0308
3H01-SL0018
3H01-221MVA
3J01-221VBA
3J01-221SK
1
3
4
1
2
2
1
2
2
1
1
1
1
1
1
1
1
1
1
1
2
1
6
10
2
1
1
2
4
2
1
1
1
1
1
1
3
6
2
2
4
4
4
4
1
2
2
1
1
1
1
1
1
4
1
1
3
1
1
1
1
1
1
1
2
3
4
5
6
7
8
9
Cylinder O-Ring*
Cylinder O-Ring*
Cylinder Sleeve
Cylinder Sleeve O-Ring*
Step Seal with O-Ring*
Quad Ring*
Back Up Ring*
U-Packing*
Dust Seal*
Piston
Valve Box
Main Valve
Upper Valve Cap
Valve Cap O-Ring*
Back Up Ring*
Valve Cap O-Ring*
Lower Valve Cap
Locater Pin
10
11
12
13
14
15
16
17
18
19
20
21
22
23
24
25
26
27
28
29
30
31
32
33
34
35
36
37
38
39
40
41
42
43
44
45
46
47
48
49
50
51
52
53
54
55
56
57
58
NI
NI
NI
NI
59
60
Box Sleeve
Box Sleeve O-Ring*
Back Up Ring*
Valve Box Set Bolt
Valve Cap Bolt
Valve Box O-Ring*
Back Cap
Back Cap O-Ring*
Plug
Cylinder O-Ring*
Buffer Ring*
Valve Box Plug
Valve Box O-Ring*
Front Cap
Front Cap Plug
Shank Bushing
Front Cap Bushing
Bushing Set Pin
Bushing Spring Pin
Nipple PF—3/4in.—1.1/16in. UN
O Ring
Side Rod Assembly
Side Rod Front Nut
Side Rod Back Nut
Side Rod Washer
Grease Nipple
Tool Stopper Pin
Tool Spring Pin
Tool Set Pin
Tool Moil (Chisel, Blunt)
Mode Valve Body
Mode Valve
Mode Valve O-Ring*
Mode Valve O-Ring*
Mode Valve Set Bolt
Mode Valve Lock Bolt
Spring Washer
Locater Pin
Stop Ring
Mode Valve Assembly
Valve Box Assembly
Seal Kit
Gas Charger
Gas Valve Assembly (Includes item # 60)
Gas Valve Cap with O-Ring
3Z01-202GC
3Z01-G00001
3Z01-G00004
*Included in seal kit only.
NI denotes not illustrated.
Effective 07/05
44
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HH 3600-2 HAMMER S/N: 5M1000 & UP
Effective 07/05
45
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HH3600-2 HAMMER
S/N 5M1000 & UP
BRACKET ASSEMBLY PARTS LIST
PART NO.
MODEL HH3600-2
3J01-221501
ITEM
QTY
DESCRIPTION
1.
2.
3.
1
1
8
Hammer Bracket (R)*
Hammer Bracket (L)*
Bracket Bolt
-----------------
3J01-221502
4.
5.
NI
6.
NI
7.
8.
9.
10.
11.
12.
Assembly of Item 3
Assembly of Item 3
3J01-221504-226
3J01-221507-298
3J01-221506-234
3J01-TC3600B
Assembly of Item 7
Assembly of Item 7
3J01-221505
8
16
2
2
4
12
12
12
4
4
1
Washer
Nut
Support Pipe (Top)
Support Pipe (Middle)
Support Pipe (Bottom)
Top Cap Bolt
Top Cap Washer
Top Cap Nut
Cushion Rubber
Screw
Assembly of Item 10
Per Carrier Model
Top Cap
*Sold as matched set w/ hardware. NI denotes not illustrated.
Prices subject to change without notice
Effective 07/05
46
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HH4500 HAMMER
ITEM
NAME
NUMBER
QTY.
1
Cylinder
3K01-2270001
3K01-09128B
3H01-09072B
3K01-2270002
3K01-07348W
3K01-170570
3K01-170573
3K01-U27000I
3K01-U27000H
3K01-D27000D
3K01-170571
3K01-2270011
3K01-2270021
3K01-2270022
3K01-2270023
3H01-07118B
3H01-08118G
3J01-051280
1
2
3
1
2
1
2
1
1
1
2
1
1
1
1
1
1
1
1
1
1
2
1
8
10
2
1
1
4
8
4
1
1
1
1
3
6
2
2
4
4
4
4
1
1
2
2
1
1
1
1
1
4
1
1
3
1
1
1
1
1
1
1
2
3
4
5
6
7
8
9
Cylinder O-Ring*
Cylinder O-Ring*
Cylinder Sleeve
Cylinder Sleeve O-Ring*
Quad Ring*
Back Up Ring*
U-Packing*
U-Packing with Back Up Ring*
Dust Seal*
10
11
12
13
14
15
16
17
18
19
20
21
22
23
24
25
26
27
28
29
30
31
32
33
34
35
36
37
38
39
40
41
42
43
44
45
46
47
48
49
50
51
52
53
54
55
56
57
NI
NI
NI
NI
58
59
Step Seal with O-Ring*
Piston
Valve Box
Main Valve
Upper Valve Cap
Valve Cap O-Ring*
Back Up Ring*
Valve Cap O-Ring*
Lower Valve Cap
Locater Pin
3K01-2270025
3Z01-PN0510
3K01-2270026
3K01-07138B
3K01-08138G
3J01-B52146
3J01-B52128
3H01-09040B
3K01-2270031
3K01-09418A
3K01-22182
Box Sleeve
Box Sleeve O-Ring*
Back Up Ring*
Valve Box Set Bolt
Valve Cap Bolt
Valve Box O-Ring*
Back Cap
Back Cap O-Ring*
Plug
Cylinder O-Ring*
Buffer Ring*
Front Cap
Front Cap Plug
Shank Bushing
Front Cap Bushing
Bushing Set Pin
Bushing Spring Pin
Nipple
3K01-9066W
3K01-8066P
3K01-2210041
3Z01-FP0038
3K01-2270042
3K01-270043
3K01-270044
3J01-S46128
3J03-N00003
3J03-07078B
3K01-270051
3K01-270052
3K01-270053
3K01-270054
3Z01-GN0018
3K01-270061
3J01-S46128
3K01-227091
3K01-227P(Fx, E)
3H01-2210027
3H01-2210028
3H01-09044W
3H01-09036W
3H01-B32068
3H01-B24040
3H01-SW0008
3H01-PN0308
3H01-SL0018
3H01-221MVA
3K01-227VBA
3K01-227SK
3Z01-202GC
3Z01-G00001
3Z01-G00004
O-Ring
Side Rod Assembly
Side Rod Front Nut
Side Rod Back Nut
Side Rod Washer
Grease Nipple
Tool Set Pin
Tool Spring Pin
Tool Stopper Pin
Tool Moil (Chisel, Blunt)
Mode Valve Body
Mode Valve
Mode Valve O-Ring*
Mode Valve O-Ring*
Mode Valve Set Bolt
Mode Valve Lock Bolt
Spring Washer
Locater Pin
Stop Ring
Mode Valve Assembly
Valve Box Assembly
Seal Kit
Gas Charger
Gas Valve Assembly (Includes item # 59)
Gas Valve Cap with O-Ring
*Included in seal kit only.
NI denotes not illustrated.
Effective 07/05
48
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HH4500 HAMMER
Effective 07/05
49
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HH4500 HAMMER
BRACKET ASSEMBLY PARTS LIST
PART NO.
MODEL HH4500
3K01-227501
-----------------
3K01-227502
ITEM
QTY
DESCRIPTION
1.
2.
3.
1
1
8
Hammer Bracket (R)*
Hammer Bracket (L)*
Bracket Bolt
4.
5.
NI
6.
NI
7.
8.
9.
10.
11.
12.
Assembly of Item 3
Assembly of Item 3
3K01-227504-262
3K01-227507-334
3K01-227504-262
3J01-TC3600B
Assembly of Item 7
Assembly of Item 7
3K01-227505
8
16
2
2
4
12
12
12
4
4
1
Washer
Nut
Support Pipe (Top)
Support Pipe (Middle)
Support Pipe (Bottom)
Top Cap Bolt
Top Cap Washer
Top Cap Nut
Cushion Rubber
Screw
Assembly of Item 10
Per Carrier Model
Top Cap
*Sold as matched set w/ hardware. NI denotes not illustrated.
Prices subject to change without notice.
Effective 07/05
50
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HH5800 HAMMER
ITEM
1
NAME
NUMBER
3L01-2330001
3J01-09108B
3J01-09138B
3H01-09072B
3L01-2330002
3L01-07378W
3L01-170580
3L01-170583
3L01-170581
3L01-U33000I
3L01-U33000H
3L01-D33000D
3L01-2330011
3L01-2330021
3L01-2330022
3L01-2330023
3K01-07138B
3K01-08138G
3L01-051480
3L01-2330025
3Z01-PN0510
3L01-2330026
3L01-07148B
3L01-08148G
3L01-B62154
3L01-B56144
3H01-09040B
3L01-2330031
3L01-09468A
3K01-2210082
3K01-09066W
3K01-08066P
3L01-2330041
3Z01-FP0038
3L01-2330042
3L01-330043
3L01-330044
3L01-S52168
3J03-N00003
3J03-07078B
3L01-230051
3L01-2330052
3L01-2330053
3L01-2330054
3Z01-GN0018
3L01-330061
3L01-S52368
3L01-233P(Fx, E)
3H01-2210027
3H01-2210028
3H01-09044W
3H01-09036W
3H01-B32068
3H01-B24040
3H01-SW0008
3H01-PN0308
3H01-SL0018
3H01-221MVA
3L01-233VBA
3L01-233SK
QTY.
Cylinder
1
2
3
4
5
6
7
8
9
Cylinder O-Ring*
Cylinder O-Ring*
Cylinder O-Ring*
Cylinder Sleeve
Cylinder Sleeve O-Ring*
Quad Ring*
Back Up Ring*
Step Seal with O-Ring*
U-Packing*
1
2
2
1
2
1
2
2
1
1
1
1
1
1
1
1
1
1
1
1
1
2
1
8
10
2
1
1
6
12
6
1
1
1
1
4
8
2
2
4
4
4
4
1
1
2
1
1
1
1
1
4
1
1
3
1
1
1
1
1
1
1
10
11
12
13
14
15
16
17
18
19
20
21
22
23
24
25
26
27
28
29
30
31
32
33
34
35
36
37
38
39
40
41
42
43
44
45
46
47
48
49
50
51
52
53
54
55
56
57
NI
NI
NI
NI
58
59
U-Packing with Back Up Ring*
Dust Seal*
Piston
Valve Box
Main Valve
Upper Valve Cap
Valve Cap O-Ring*
Back Up Ring*
Valve Cap O-Ring*
Lower Valve Cap
Locater Pin
Box Sleeve
Box Sleeve O-Ring*
Back Up Ring*
Valve Box Set Bolt
Valve Cap Bolt
Valve Box O-Ring*
Back Cap
Back Cap O-Ring*
Plug
Cylinder O-Ring*
Buffer Ring*
Front Cap
Front Cap Plug
Shank Bushing
Front Cap Bushing
Bushing Set Pin
Bushing Spring Pin
Nipple
O-Ring
Side Rod Assembly
Side Rod Front Nut
Side Rod Back Nut
Side Rod Washer.
Grease Nipple
Tool Set Pin
Tool Spring Pin
Tool Moil (Chisel, Blunt)
Mode Valve Body
Mode Valve
Mode Valve O-Ring*
Mode Valve O-Ring*
Mode Valve Set Bolt
Mode Valve Lock Bolt
Spring Washer
Locater Pin
Stop Ring
Mode Valve Assembly
Valve Box Assembly
Seal Kit
Gas Charger
3Z01-202GC
3Z01-G00001
3Z01-G00004
Gas Valve Assembly (Includes item # 59)
Gas Valve Cap with O-Ring
*Included in seal kit only.
NI denotes not illustrated.
Effective 07/05
52
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HH5800 HAMMER
Effective 07/05
53
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HH5800 HAMMER
BRACKET ASSEMBLY PARTS LIST
PART NO.
MODEL HH5800
3L01-233501
-----------------
3L01-233502
ITEM
QTY
DESCRIPTION
1.
2.
3.
1
1
8
Hammer Bracket (R)*
Hammer Bracket (L)*
Bracket Bolt
4.
5.
NI
6.
NI
7.
8.
9.
10.
11.
12.
Assembly of Item 3
Assembly of Item 3
3L01-233504-284
3L01-233507-364
3L01-233504-284
3J01-TC3600B
Assembly of Item 7
Assembly of Item 7
3L01-233505
8
16
2
2
4
12
12
12
4
4
1
Washer
Nut
Support Pipe (Top)
Support Pipe (Middle)
Support Pipe (Bottom)
Top Cap Bolt
Top Cap Washer
Top Cap Nut
Cushion Rubber
Screw
Assembly of Item 10
Per Carrier Model
Top Cap
*Sold as matched set w/ hardware. NI denotes not illustrated.
Prices subject to change without notice.
Effective 07/05
54
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HH8000 HAMMER
ITEM
NAME
NUMBER
3M01-2400001
3L01-09138B
3M01-09098B
3H01-09072B
3M01-2400002
3M01-07398W
3M01-170590
3M01-170593
3M01-170591
3M01-U40000I
3M01-U40000H
3M01-D40000D
3M01-2400011
3M01-2400021
3M01-2400022
3M01-2400023
3K01-07138B
3K01-08138G
3M01-051480
3M01-2400025
3Z01-PN0510
3M01-2400026
3M01-07158B
3M01-08158G
3L01-B62154
3L01-B56144
3H01-09040B
3M01-2400031
3M01-09488A
3J01-240081
QTY.
1
Cylinder
1
2
1
2
1
2
1
2
2
1
1
1
1
1
1
1
1
1
1
1
1
1
2
1
2
10
2
1
1
5
10
5
1
1
1
1
4
8
2
2
4
4
4
4
1
1
2
1
1
1
1
1
4
1
1
3
1
1
1
1
1
1
1
2
3
4
5
6
7
8
9
Cylinder O-Ring*
Cylinder O-Ring*
Cylinder O-Ring*
Cylinder Sleeve
Cylinder Sleeve O-Ring*
Quad Ring*
Back Up Ring*
Step Seal with O-Ring*
U-Packing*
10
11
12
13
14
15
16
17
18
19
20
21
22
23
24
25
26
27
28
29
30
31
32
33
34
35
36
37
38
39
40
41
42
43
44
45
46
47
48
49
50
51
52
53
54
55
56
57
NI
NI
NI
NI
58
59
U-Packing with Back Up Ring*
Dust Seal*
Piston
Valve Box
Main Valve
Upper Valve Cap
Valve Cap O-Ring*
Back Up Ring*
Valve Cap O-Ring*
Lower Valve Cap
Locater Pin
Box Sleeve
Box Sleeve O-Ring*
Back Up Ring*
Valve Box Set Bolt
Valve Cap Bolt
Valve Box O-Ring*
Back Cap
Back Cap O-Ring*
Plug
Cylinder O-Ring*
Buffer Ring*
Front Cap
Front Cap Plug
Shank Bushing
Front Cap Bushing
Bushing Set Pin
Bushing Spring Pin
Nipple
3J01-09076W
3J01-08076P
3M01-2400041
3Z01-FP0038
3M01-2400042
3M01-2400043
3M01-2400044
3L01-S52168
3M03-N00004
3M03-07098B
3M01-2400051
3M01-2400052
3M01-2400053
3M01-2400054
3Z01-GN0018
3M01-400061
3L01-S52368
3M01-240P(Fx, E)
3H01-2210027
3H01-2210028
3H01-09044W
3H01-09036W
3H01-B32068
3H01-B24040
3H01-SW0008
3H01-PN0308
3H01-SL0018
3H01-221MVA
3M01-240VBA
3M01-240SK
3Z01-202GC
O-Ring
Side Rod Assembly
Side Rod Front Nut
Side Rod Back Nut
Side Rod Washer.
Grease Nipple
Tool Set Pin
Tool Spring Pin
Tool Moil (Chisel, Blunt)
Mode Valve Body
Mode Valve
Mode Valve O-Ring*
Mode Valve O-Ring*
Mode Valve Set Bolt
Mode Valve Lock Bolt
Spring Washer
Locater Pin
Stop Ring
Mode Valve Assembly
Valve Box Assembly
Seal Kit
Gas Charger
Gas Valve Assembly (Includes item # 59)
Gas Valve Cap with O-Ring
3Z01-G00001
3Z01-G00004
*Included in seal kit only.
NI denotes not illustrated.
Effective 07/05
56
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HH8000 HAMMER
Effective 07/05
57
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HH8000 HAMMER
BRACKET ASSEMBLY PARTS LIST
PART NO.
MODEL HH8000
3M01-240501
-----------------
3M01-240502
ITEM
QTY
DESCRIPTION
1.
2.
3.
1
1
8
Hammer Bracket (R)*
Hammer Bracket (L)*
Bracket Bolt
4.
5.
NI
6.
NI
7.
8.
9.
10.
11.
12.
Assembly of Item 3
Assembly of Item 3
3M01-240504-304
3M01-240507-384
3M01-240504-304
3M01-TC8000B
Assembly of Item 7
Assembly of Item 7
3M01-240505
8
16
2
2
4
12
12
12
4
4
1
Washer
Nut
Support Pipe (Top)
Support Pipe (Middle)
Support Pipe (Bottom)
Top Cap Bolt
Top Cap Washer
Top Cap Nut
Cushion Rubber
Screw
Assembly of Item 10
Per Carrier Model
Top Cap
*Sold as matched set w/ hardware. NI denotes not illustrated.
Prices subject to change without notice.
Effective 07/05
58
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NOTES
59
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HYDRAULIC HAMMERS
IPC INDUSTRIES, INC.
194 N. Brandon Dr.
Glendale Heights, IL 60139
TOLL FREE (800) 487-5431
Phone: (630) 893-5558 Fax: (630) 790-3751
rev: 7/05
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